OSHA Inspection: BRIDESBURG FOUNDRY, INC.

Issued

Mar 27, 2020

Abate by

Apr 6, 2020

Penalty

Initial $6,882 · Current $4,391 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, was not provided, used, and maintained in a sanitary and reliable condition.     a) Melting Department: The Pourer and Ladle Leader were pouring molten metal above the height of the aluminized leggings worn and were exposed to molten metal or sparks entering their boots, on or about November 8, 2019.    Abatement certification required within 10 days after abatement date.  The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Apr 16, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(d)(1)(i): The employer did not select and have each affected employee use the types of personal protective equipment (PPE) that would protect the affected employee(s) from the hazards identified in the hazard assessment.  a) Melting Department: The hazard assessment conducted did not select appropriate personal protective equipment to protect employees exposed to burns from molten metal, on or about November 8, 2019.   Abatement certification required within 10 days after abatement date.  The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Penalty

Initial $6,882 · Current $4,389 Reduced

General-duty citation text

29 CFR 1910.132(e): The employer did not remove from service defective or damaged personal protective equipment.    a) Melting Department: The Pourer and Ladle Leader were wearing aluminized leggings that were damaged and the defective personal protective equipment was not removed from service, on or about November 8, 2019.    No abatement certification or documentation required.

Issued

Mar 27, 2020

Abate by

Apr 6, 2020

Penalty

Initial $5,735 · Current $3,244 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.134(h)(2)(i): Respirators were not stored to protect them from damage, contamination, dust, sunlight, extreme temperatures, excessive moisture, and damaging chemicals or  were not packed or stored to prevent deformation of the facepiece and exhalation valve:     a) No Bake Area: Elastomeric and filtering facepiece respirators were not properly stored during breaks and lunch, exposing employees to silica contamination and dust, on or about December 6, 2019.    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Apr 6, 2020

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR 1910.134(k)(1)(v): The employer did not ensure that each user could demonstrate knowledge of the procedures for respirator maintenance and storage:   a) No Bake Area: Employees were required to wear respirators and the employer did not ensure employees could demonstrate knowledge of the procedures for maintenance and storage of the respirator, on or about December 6, 2019.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Jan 3, 2023

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(c): The employer did not ensure that no employee was exposed to an airborne concentration of respirable crystalline silica in excess of 50 ug/m3, calculated as an 8-hour TWA:    a) No Bake Area: An employee, Mold Assembler, assembling and checking molds was exposed to an 8 hour time-weighted average (TWA) of 99.92 ug/m³ of respirable silica. This level is 2.0 times the permissible exposure limit of 50 ug/m³. This exposure occurred over a 436 minute sampling period on December 6, 2019. A zero exposure is assumed for the 44 minutes not sampled.      b) No Bake Area: An employee, No Bake Team Lead, operating the shaker and the mixer was exposed to an 8 hour time-weighted average (TWA) of 123.02 ug/m³ of respirable silica. This level is 2.46 times the permissible exposure limit of 50 ug/m³. This exposure occurred over a 444 minute sampling period on December 6, 2019. A zero exposure is assumed for the 36 minutes not sampled.

Issued

Mar 27, 2020

Abate by

May 6, 2020

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(e)(1): The employer did not establish a regulated area wherever an employee's exposure to airborne concentrations of respirable crystalline silica is, or can reasonably be expected to be, in excess of the PEL.    a) No Bake Area: Employees were exposed to silica at levels greater than the permissible exposure limit and a regulated area was not established with demarcation and signs, on or about December 6, 2019. (See Citation 1, Item 3c for description of overexposures)    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Jan 3, 2023

Penalty

Initial $0 · Current $0

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(f)(1): The employer did not use engineering and work practice controls to reduce and maintain employee exposure to respirable crystalline silica to or below the PEL, unless the employer can demonstrate that such controls are not feasible:    a) No Bake Area: An employee, Mold Assembler, assembling and checking molds was exposed to silica at levels greater than the permissible exposure limit of 50 ug/m³ and feasible engineering controls and work practices were not installed, on or about December 6, 2019. (See Citation 1, Item 3c for full description)      b) No Bake Area: An employee, No Bake Team Lead, operating the shaker and the mixer was exposed to silica at levels greater than the permissible exposure limit of 50 ug/m³ and feasible engineering controls and work practices were not installed, on or about December 6, 2019. (See Citation 1, Item 3c for full description)      Feasible abatement methods include but are not limited to:      ABATEMENT STEPS ARE AS FOLLOW:  1. Install adequate local exhaust ventilation at the mixer.  2. Enclose the shaker allowing access to deposit completed molds and to the screen. Design work practices so that employees are not in the shaker enclosure while silica levels are elevated.  3. Install adequate local exhaust ventilation around the shaker.  4. Disperse a sweeping compound in and around the molding lines throughout the day to reduce the amount of silica dust becoming airborne. Develop a housekeeping plan for the area.  5. Develop a job rotation schedule so that employees in the No Bake Area can rotate to a position with no to little silica exposure.      STEP 1 - A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with the dates required by this citation:      1.  Evaluation of engineering control options;      2.  Selection of optimum control method and completion of design;      3.  Procurement, installation and operation of selected control measures;      4.  Testing and acceptance or modification/redesign of controls.      Note: All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person. Ninety- (90) day progress reports are required during the abatement period.  (The 90 day requirement can be shortened or lengthened by the area director depending on the specific circumstances.)      STEP 2 - Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.

Issued

Mar 27, 2020

Abate by

Jul 30, 2020

Penalty

Initial $5,735 · Current $3,244 Reduced

Hazardous substances 9000

General-duty citation text

29 CFR 1910.1053(i)(2): The employer did not make available an initial (baseline) medical examination within 30 days after initial assignment when the employee had not received a medical examination that meets the requirements of this section within the last three years:    a) No Bake Area: Employees, Mold Closure/Assembler and Team Leader, working in job positions having personal exposures greater than the permissible exposure level of 50 ug/m3 of respirable silica were not provided initial baseline medical examinations within 30 days of assignment to the area, on or about December 6, 2019.    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Jul 30, 2020

Penalty

Initial $5,735 · Current $3,244 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(c)(1): Employee(s) were exposed to lead at concentrations greater than fifty micrograms per cubic meter of air averaged over an eight-hour period:    a) Grinding Department: An employee, Grinder, using belt sanders and pneumatic handheld grinders to finish various products was exposed to an 8 hour time-weighted average (TWA) of 86 ug/m³of lead. This level is 1.7 times the permissible exposure limit of 50 ug/m³. This exposure occurred over a 360 minute sampling period on December 5, 2019. A zero exposure is assumed for the 120 minutes not sampled.    Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states that employees and their representatives were informed of this abatement.

Issued

Mar 27, 2020

Abate by

Jul 30, 2020

Penalty

Initial $0 · Current $0

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(e)(1)(i): For any employees exposed to lead above the permissible exposure limit for more than 30 days per year the employer did not implement engineering and work practice controls (including administrative controls) were not implemented to reduce and maintain employee exposure to lead :   a) Grinding Department: An employee, Grinder, using belt sanders and pneumatic handheld grinders to finish various products was exposed to lead at levels greater than the permissible exposure limit and engineering controls were not installed, on or about December 5, 2019. (See Citation 1, Item 5a for full description)    Feasible abatement methods include but are not limited to: 1. Installing a downdraft table next to the belt sanders to be used when the pneumatic grinder is required. 2. Institute a work rule that no grinding or polishing can be conducted without ventilation. Ensure employees are trained on the work rule and that the work rule is enforced.    ABATEMENT STEPS ARE AS FOLLOW:    STEP 1  A written detailed plan of abatement shall be submitted to the Area Director outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposures to hazardous substances as referenced in this citation. This plan shall include, at a minimum, target dates for the following actions which must be consistent with the dates required by this citation:    1.  Evaluation of engineering control options;    2.  Selection of optimum control method and completion of design;    3.  Procurement, installation and operation of selected control measures;    4.  Testing and acceptance or modification/redesign of controls.    Note: All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person. Ninety- (90) day progress reports are required during the abatement period.  (The 90 day requirement can be shortened or lengthened by the area director depending on the specific circumstances.)    STEP 2 - Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.

Issued

Mar 27, 2020

Penalty

Initial $5,735 · Current $3,244 Reduced

Hazardous substances 1591

General-duty citation text

29 CFR 1910.1025(g)(1)(i): The employer did not provide, at no cost to the employee, and ensure that the employee used appropriate protective work clothing and equipment that prevented contamination of the employee and the employee's garments, such as, but not limited to coveralls or similar full-body work clothing:     a) Melting Department: New employees working as Ladle Leaders were working in a position where employee exposure to lead was greater than the permissible exposure limit and the employees were not provided coveralls or full body work clothing for the first 60 days of their tenure, on or about November 8, 2019.    No abatement certification or documentation required.

Issued

Mar 27, 2020

Penalty

Initial $5,735 · Current $3,244 Reduced

General-duty citation text

29 CFR 1904.39(a)(2): The employer did not report within 24-hours a work-related incident resulting in in-patient hospitalization, amputation or the loss of an eye.    a) Melting Department: On October 29, 2019, an employee suffered severe burns requiring hospitalization which was not reported within 24 hours of the incident, on or about November 8, 2019.    No abatement certification or documentation required.